Spindle and Spindle Attachments for Coreless and Flexible Core Rolled Tissue Products

ABSTRACT

Spindles attachments and replacement spindles for use with a coreless tissue roll or a flexible core rolled tissue product are generally disclosed. In one embodiment, a spindle attachment having an elongated tube is generally disclosed. Each end portion of the spindle attachment is tapered at an angle of less than 45°. The elongated tube defines a circular opening that extends through the center of the elongated tube. In another embodiment, an armed spindle for use in place of a traditional spindle is generally disclosed. The armed spindle includes a pair of opposing pegs connected to at least 4 arms. Each arm has a pair of end portions that extend away from the center axis of the armed spindle to a middle portion. 
     Also, a kit is disclosed that includes both a spindle attachment or an armed spindle and at least one rolled tissue product.

BACKGROUND OF THE INVENTION

Commercial and consumer absorbent products such as shop towels, nonwovenfabrics, wipers, toilet tissue and paper towels are often packaged,distributed, and dispensed in roll format. Most products in this formatinclude a cylindrical core at the center of the roll. Typically, theabsorbent product is wrapped about the core. Most roll format productdispensers require this core to function properly. The core is usuallysome type of stiff cardboard tube, plastic tube, or solid spindle whichis glued to the product so that the product does not separate from thecore.

The absorbent product is normally loaded by mounting the roll on aspindle in a manner similar to the ubiquitous bathroom toilet rolldispenser. The spindle passes through or otherwise penetrates the innerspace of the core. Some dispensers include pegs that penetrate thehollow space within the core for only a limited extent, as demonstratedin U.S. Pat. Nos. 390,084 and 2,905,404 to Lane and Simmons,respectively.

Recently, coreless rolls of products such as, for example, toilet tissuehave appeared on the market, primarily in Europe. These coreless rollsare wound throughout the entire diameter of the roll. There areadvantages and disadvantages associated with the coreless rolls.Coreless rolls are ecologically superior to cored rolls because theylack the central core made of plastic, cardboard or other material. Inaddition, more product can be provided in the space that would otherwisehave been occupied by the core. Cored rolls are more expensive tomanufacture than coreless rolls because of the expense of making thecores and joining the cores to the product.

On the other hand, coreless roll products have dispensing problems thatare difficult to overcome. Coreless rolls may not dispense properly on aconventional core roll dispenser. Conventional dispensers for corelessrolls typically include an enclosed surface that supports the roll as itturns, and an opening through which the product is passed. Whilefunctional, these dispensers have some undesirable characteristics,including an inability to control drag resistance to withdrawal of theproduct; the fact that the product actually touches the inside of thedispenser, which might be considered unsanitary by some consumers; andan inability to provide 180 degree product access to the consumer. Somedispensers for coreless rolls have pressure plates and pins that projectinto the side of the roll between the layers of product. It can bedifficult to center the roll during loading of these dispenser without acentering device and the pressure plate and pins can easily be priedback to release the roll from the dispenser.

Accordingly, a need exists for an adapter to convert conventional coredroll dispensers to handle flexible core tissue rolls. Additionally, aneed exists for a spindle replacement designed for coreless and flexiblecore rolls that can be substituted for a conventional dispenser.

SUMMARY OF THE INVENTION

In general, the present disclosure is directed to spindles attachmentsand replacement spindles for use with a coreless tissue roll or aflexible core rolled tissue product. For example, in one embodiment, aspindle attachment having an elongated tube is generally disclosed. Eachend portion of the spindle attachment is tapered at an angle of lessthan 45°, such as from about 20° to about 40°. The middle portion issubstantially cylindrical in shape. The elongated tube defines acircular opening that extends through the center of the elongated tubefrom one end portion to the opposition end portion. The opening has aninner diameter of from about 0.75 inches to about 1.25 inches.

The middle portion defines an outer surface that can have an outerdiameter of about 1.25 inches to about 2 inches, such as from about 1.5inches to about 1.75 inches, or from about 1.45 inches to about 1.6inches. Each end portion and the middle portion collectively define anouter surface that can be coated with an lubricating coating that lowersthe coefficient of friction of the outer surface. Also, each end portionand the middle portion can collectively define a grooved outer surface.

In another embodiment, an armed spindle for use in place of atraditional spindle is generally disclosed. The armed spindle includes apair of opposing pegs that define a center axis of the armed spindleextending through the center portion of each opposing peg. At least 3arms (such as at least 4 arms) are each in contact with each opposingpeg. Each arm has a pair of end portions that extend away from thecenter axis of the armed spindle to a middle portion. The arms areconfigured to rotate about the center axis from a substantially flatposition to a rotating position where the arms are spaced apart in asubstantially equal distance. For example, when the armed spindle has 4arms, the arms are configured to rotate about the center axis from asubstantially flat position to a cross-like shape. Alternatively, whenthe armed spindle has 6 arms, the arms are configured to rotate aboutthe center axis from a substantially flat position to a hexagonal-likeshape. In one particular embodiment, oppositely positioned arms move inconcert with each other, but independently from adjacently positionedarms.

In yet another embodiment, a kit is disclosed that includes both aspindle attachment or an armed spindle and at least one rolled tissueproduct. The rolled tissue product includes a nonwoven tissue webcomprising pulp fibers wound about a flexible core. The flexible corecomprises a polymeric sheet of synthetic polymers. The nonwoven tissueweb and the flexible core are attached to each other at an inner layerof the nonwoven tissue web by an attachment mechanism. The tissue sheethas a tensile strength in the machine direction that is weaker than thestrength of the flexible core. In a particular embodiment, the flexiblecore defines an inner diameter that is from about 0.1% to about 5%greater than the outer diameter of the middle portion of the spindleattachment or spindle replacement.

Other features and aspects of the present invention are discussed ingreater detail below.

DEFINITIONS

“Roll Bulk” can be calculated by two different methods:

-   -   1. roll bulk (cc/g)=3.142×(Roll Diameter squared (cm²)−outer        Core Diameter squared (cm²))/(4×Sheet length (cm)×sheet        count×Basis Weight (g/cm²))        or    -   2. roll bulk (cc/g)=0.785×(Roll Diameter squared (cm²)−outer        Core Diameter squared (cm²))/(Sheet length (cm)×sheet        count×Basis Weight (g/cm²)).

Tissue products can be distinguished from other paper products in termsof their bulk. For various rolled products of this invention, the singlesheet bulk of the sheet on the roll can be about 5 cc/g am or greater,such as about 7 cc/g or greater, such as about 8 cc/g or greater, suchas from about 6 cc/g to about 24 cc/g.

Single sheet bulk is calculated by taking the single sheet caliper anddividing by the conditioned basis weight of the product. The term“caliper” as used herein is the thickness of a single tissue sheet, andmay either be measured as the thickness of a single tissue sheet or asthe thickness of a stack of ten tissue sheets and dividing the tentissue sheet thickness by ten, where each sheet within the stack isplaced with the same side up. Caliper is expressed in microns. Caliperis measured in accordance with TAPPI test methods T402 “StandardConditioning and Testing Atmosphere For Paper, Board, Pulp Handsheetsand Related Products” and T411 om-89 “Thickness (caliper) of Paper,Paperboard, and Combined Board” optionally with Note 3 for stackedtissue sheets. The micrometer used for carrying out T411 om-89 is a BulkMicrometer (TMI Model 49-72-00, Amityville, N.Y.) or equivalent havingan anvil diameter of 4 1/16 inches (103.2 millimeters) and an anvilpressure of 220 grams/square inch (3.3 g kilo Pascals).

The basis weight and bone dry basis weight of the tissue sheet specimensare determined using TAPPI T410 procedure or a modified equivalent suchas: Tissue samples are conditioned at 23.degree. C.+−.1.degree. C. and50.+−.2% relative humidity for a minimum of 4 hours. After conditioninga stack of 16″-3″×3″ samples is cut using a die press and associateddie. This represents a tissue sheet sample area of 144 in² or 929 cm².Examples of suitable die presses are TMI DGD die press manufactured byTesting Machines, Inc., Islandia, N.Y., or a Swing Beam testing machinemanufactured by USM Corporation, Wilmington, Mass. Die size tolerancesare .+−.0.008 inches in both directions. The specimen stack is thenweighed to the nearest 0.001 gram on a tared analytical balance. Thebasis weight in grams per square meter is calculated using the followingequation: Basis weight=stack wt. in grams/0.0929.

A sheet of tissue can be defined as the material between the adjacentlines of weakness in the continuous sheet that comprises the rolledproduct. The sheet length is defined as the distance between adjacentlines of weakness and the sheet width as defined as the edge to edgedistance of the sheet perpendicular to the sheet length. For example,sanitary bath products preferably have single sheet lengths of fromabout 3 inches to about 8 inches, such as from about 3.25 inches toabout 7 inches such as from about 3.5 inches to about 6 inches, such asfrom about 3.75 inches to about 5 inches. The sanitary bath products ofthe present invention preferably have sheet widths of from about 3inches to about 6 inches, such as from about 3.25 inches to about 5inches such as from about 3.5 inches to about 4.75 inches.

The Basis Weight of a sheet is usually expressed in ounces of materialper square yard (osy) or grams per square meter (gsm). (Note that toconvert from osy to gsm, multiply osy by 33.91.)

A “synthetic polymer” as defined herein refers to a polymer which is notfound as is in nature. The synthetic polymers have been altered by aprocessing step to create a polymer having physical or chemicalproperties unique to the natural world via human intervention. Suchpolymers may or may not be derived from materials from sustainableresources. Sustainable resources are resources which can be replenishedon an on-going basis. Sustainable resources include living plants andanimals and in particular those plants and animals grown underagricultural or domesticated conditions. Most commonly, sustainablematerials typically are sourced from agricultural crops or similar plantbased materials. Cellulose fibers and cotton fibers are not syntheticpolymers, however, rayon derived from cellulose fibers would beconsidered a synthetic polymer for the purposes of the presentinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including thebest mode thereof to one of ordinary skill in the art, is set forth moreparticularly in the remainder of the specification, including referenceto the accompanying figures in which:

FIG. 1 shows an exemplary spindle attachment for use with a corelesstissue product or a tissue product having a flexible core;

FIGS. 2A and 2B depict an exemplary spindle for use with a corelesstissue product or a tissue product having a flexible core;

FIG. 3 shows a traditional spindle for use with conventional toilettissue products;

FIG. 4 is a prospective view of an exemplary rolled tissue producthaving a flexible core;

FIG. 5 is a prospective view of a stack of exemplary rolled tissueproducts having a flexible core;

FIG. 6 is a side view of a stack of exemplary rolled tissue productshaving a flexible core packaged in a packaging material;

FIGS. 7A and 7B are different views of another exemplary rolled tissueproduct with a flexible core having tabs marking the core;

FIG. 8 shows a side view of an exemplary rolled tissue product having aflexible core;

FIG. 9 is a schematic diagram of a tissue web forming machine,illustrating the formation of a stratified tissue web having multiplelayers in accordance with the present disclosure;

FIG. 10 is a schematic diagram of one embodiment of a process forforming uncreped through-dried tissue webs for use in the presentdisclosure;

FIG. 11 is a schematic diagram of one embodiment of a process forforming wet creped tissue webs for use in the present disclosure;

FIG. 12 is a side view of a traditional spindle in use with a rolledtissue product;

FIG. 13 is a side view of a traditional spindle in use with a deformedrolled tissue product;

FIGS. 14A and 14B are prospective views of an expanding spindle;

FIGS. 15A and 15B are prospective views of an expanding spindle havingtapered end portions; and

FIG. 16 is a side view of an expanding spindle having the middle portionexpanded to give shape definition to the flexible core rolled tissueproduct.

Repeat use of reference characters in the present specification anddrawings is intended to represent same or analogous features or elementsof the present disclosure.

DETAILED DESCRIPTION

Reference now will be made to the embodiments of the invention, one ormore examples of which are set forth below. Each example is provided byway of an explanation of the invention, not as a limitation of theinvention. In fact, it will be apparent to those skilled in the art thatvarious modifications and variations can be made in the inventionwithout departing from the scope or spirit of the invention. Forinstance, features illustrated or described as one embodiment can beused on another embodiment to yield still a further embodiment. Thus, itis intended that the present invention cover such modifications andvariations as come within the scope of the appended claims and theirequivalents. It is to be understood by one of ordinary skill in the artthat the present discussion is a description of exemplary embodimentsonly, and is not intended as limiting the broader aspects of the presentinvention, which broader aspects are embodied exemplary constructions.In general, the present disclosure is directed to a spindle attachmentor spindle replacement for use with a coreless rolled tissue product ora rolled tissue product having a flexible core.

A suitable spindle attachment can be included to mount over atraditional spindle. A traditional spindle 200 is shown in FIG. 3. Thetraditional spindle has a first tube 202 and a second tube 204 that areconfigured in a telescopically arrangement. Specifically, the secondtube 204 has a slightly wider inner diameter so that the first tube 202can slide within the inner diameter of the second tube 204. Internally,a spring (not shown) is provided within the center of the first andsecond tubes 202, 204 so that the tubes are biased away from each other.Thus, the length L_(t) of the traditional spindle can vary, but isgenerally designed to fit within a pair of spindle holders (not shown).The pegs 206, 208 are positioned along the ends of each tube 202, 204,respectively, to secure the traditional spindle in the spindle holder.

However, this traditional spindle 200 presents several problems whenused with a flexible core tissue roll of the present invention. Forexample, since the flexible core may not be perfectly circular (such asshown in FIG. 8), the roll may not spin well on the spindle. Referringto FIG. 12, a traditional rolled tissue product 300 is shown having astiff cardboard core 302. The traditional rolled tissue product 300rests on the spindle 304 such that the axis of rotation is on thespindle, not the center of the roll. Additionally, when rotating, theaxis of rotation of the roll varies as the roll bounces and moves aboutthe spindle 304. When the traditional rolled tissue product 300 isflattened, the deformed core 302 does not rotate smoothly about thespindle 304, such as shown in FIG. 13.

This problem is especially present when there is a significantdifference in the outer diameter d_(T) and the inner diameter defined bythe inner surface of the flexible core of the rolled tissue product.This difference is present in most circumstances because the traditionalspindle typically has an outer diameter d_(T) from about 0.75 inches toabout 1 inch while the inner diameter defined by the inner surface ofthe flexible core of the rolled tissue product is typically from about1.25 inches to about 2 inches, such as from about 1.5 inches to about1.75 inches.

Additionally, the traditional spindle can create problems when mountingthe flexible core tissue roll. For instance, the 90° angles formed bythe cylindrical shape of both the first and second tubes 202, 204 andthe pins 206, 208 can be difficult to insert into the flexible core ofthe rolled tissue product. In some instances, these sharp edges can tearor otherwise damage the flexible core member during insertion.

In order to overcome these problems associated with using thetraditional spindles with the flexible core rolled tissue products ofthe present disclosure, the present inventors have created speciallydesigned spindle attachments and spindles.

I. Spindle Attachments

First, referring to FIG. 1, a spindle attachment 210 is shown. In thisembodiment, the spindle attachment 210 is designed for use with atraditional spindle (such as shown in FIG. 3). As shown, the spindleattachment 210 has an inner opening 212 extending the entire lengthL_(SA) of the spindle attachment 210. This inner opening is designed toaccommodate insertion of a standard bath or towel spindle as well asallow the spindle to fit the so called j-hook bath tissue dispensers.J-hook dispensers typically are designed as a rod perpendicularlyextending from a wall. The end of the rod farthest from the wall whenperpendicularly extended is turned upwards or flared slightly. In normaluse, the core is slid over the rod and the roll rotates about the rod.The upward or flared end prevents the roll from sliding off the rodduring use. The inner opening 212 has an inner diameter d_(I) that islarger than the spindle to which it is desired to be attached. In oneembodiment, the inner diameter d_(I) of the inner opening 212 rangesfrom about 0.75 inches to about 1.25 inches. However, the inner diameterd_(I) does not have to closely match the outer diameter d_(τ) of thetraditional spindle 200 in order to function properly.

In use, a flexible core rolled tissue product can be mounted onto thespindle attachment 210. Each of the ends of the spindle attachment 210includes a tapered section 214 that gradually increases the width of thespindle attachment 210 from the inner diameter d_(I) to the outerdiameter d_(O) of the middle section 216. In one particular embodiment,the tapered sections 214 have an angle of less than about 55° or lessthan about 45°, such as from about 20° to about 40°. These tapered endsections 214 help a user insert the spindle attachment 210 into theflexible core of a rolled tissue product. By gradually increasing indiameter, the spindle attachment 210 can be more easily inserted intothe flexible core, when compared to a traditional spindle. Additionally,the gradual increase in diameter of the tapered sections 214 can helpprevent the spindle attachment 210 from damaging the flexible core ofthe rolled tissue product.

The middle section 216 has an outer diameter d_(O) that is configured toclosely match the inner diameter defined by the flexible core of therolled tissue product (e.g., is less from about 0.001 inch to about 0.1inch less than the diameter of the flexible core). For example,depending on the inner diameter of the flexible core rolled tissueproduct, the outer diameter d_(O) can range from about 1.25 inches toabout 2 inches, such as from about 1.5 inches to about 1.75 inches. Inone particular embodiment, the outer diameter d_(O) can be from about1.45 inch to about 1.6 inches. Thus, once mounted onto the spindleattachment 210, the flexible core rolled tissue product will be shapedto be substantially round by the middle section 216. As such, theflexible core rolled tissue product will rotate smoothly and properly ona traditional spindle.

Additionally, an outer coating can be applied to the outer surface ofthe spindle attachment 210 in order to reduce the coefficient offriction between the spindle attachment and the flexible core.

Alternatively, or additionally, the outer surface can be grooved toreduce the contact area of the spindle attachment surface and theflexible core. Thus, less frictional forces are asserted between the twowhen the rolled tissue product is mounted on the spindle attachment.

After mounting the flexible core rolled tissue product onto the spindleattachment 210, the spindle attachment 210 can then be mounted onto atraditional spindle (such as the traditional spindle 200 shown in FIG.3). The overall length L_(SA) of the spindle attachment 210 is less thanthat of the traditional spindle 200, such that the spindle attachment210 can be mounted onto a traditional spindle while still allowing thetraditional spindle to be mounted onto the mounting brackets.

In one embodiment, at least one spindle attachment 210 and at least oneflexible core rolled tissue product can be included within a kit. Bypackaging the spindle attachment 210 together with the flexible corerolled tissue product, the outer diameter d_(O) of middle section 216 onthe spindle attachment 210 can be uniquely matched to the inner diameterdefined by the inner surface of the flexible core on the rolled tissueproduct. For example, the outer diameter d_(O) of the spindle attachment210 can from about 0.1% to about 5% smaller (in diameter) than the innerdiameter defined by the inner surface of the flexible core in the kit.

II. Spindle Replacement

Although the spindle attachment 210 of FIG. 1 is shown for use with atraditional spindle, a spindle replacement can be designed having asimilar overall design. For example, the spindle replacement can havesubstantially the same outer appearance (e.g., tapered ends and a largermiddle portion), but can be provided with outer pegs for use intraditional mounting brackets (instead of having openings in each end).In this embodiment, the spindle replacement can be separated into twopieces and telescopically arranged with a spring internally positioned,as described with respect to FIG. 3.

In another embodiment, the flexible core rolled tissue product can beprovided in a kit with a spindle replacement that is designed toovercome the problems associated with the traditional spindle 200. Forexample, referring to FIGS. 2A and 2B, an armed spindle 220 is shown.The armed spindle 220 can be used in place of a traditional spindle. Thearmed spindle 220 is shown having four arms 222 a-222 d that areconnected on each end by pegs 224 a, 224 b. Each arm 222 a-222 d istapered on towards the end portions of the arm. Thus, each arm 222 a-222d gradually increases in distance away from the axis X defined throughthe center of each peg 224 a, 224 b. Due to this tapered increase indiameter (i.e., distance away from the axis X defined through the centerof each peg 224 a, 224 b), the armed spindle 220 can be more easily slidinto a flexible core of a rolled tissue product, when compared to atraditional spindle.

Additionally, the arms 222 a-222 d of the armed spindle 220 can beconfigured such that they can be interchanged between a substantiallyflat orientation and a rotating position having each arm spaced apart ina substantially equal distance. For example, referring to FIG. 2A, thearms 222 a-222 d can be oriented in a cross-like shape, such that eacharm is substantially equally spaced apart from each other. Thiscross-like shape can help give the flexible core of the rolled tissueproduct definition during use. Thus, the rolled tissue product can spinmore smoothly once mounted on the armed spindle 220 and the spindle isoriented in a cross-like shape.

On the other hand, the arms 222 a-222 d of the armed spindle 220 can belaid substantially flat to facilitate the insertion of the armed spindle220 into the flexible core of the rolled tissue product, such as shownin FIG. 2B. In this orientation, the armed spindle 220 can more closelyresemble the substantially linear shape of the flexible core of therolled tissue product after it is removed from its packaging. As such,the arms 222 a-222 d of the armed spindle 220 can be more easilyinserted into the flexible core. After being inserted into the flexiblecore, the arms 222 a-222 d of the armed spindle 220 can be rotated tothe cross-like orientation shown in FIG. 2A and described above.

Rotation between the substantially flat orientation and the cross-likeorientation can be accomplished according to any method. For example, inthe shown embodiments, oppositely positioned arms move in concert witheach other but independent of their neighboring arms. Referring to FIGS.2A and 2B, arms 222 a and 222 c move in concert with each other, butindependently from arms 222 b and 222 d. The opposite is also true: arms222 b and 222 d move in concert with each other, but independently fromarms 222 a and 222 c.

Although the embodiment shown in FIGS. 2A and 2B includes 4 arms 222a-222 d on the armed spindle 220, any number of arms can be includedwithin the scope of the present disclosure. For example, the armedspindle 220 can have from 4 arms to 8 arms. In one particularembodiment, the armed spindle 220 can have 6 arms. Likewise, the armedspindle can have as few as 3 arms. Thus, any reasonable number of arms(at least 3) can be used. Additionally, the armed spindle can beprovided with an outer surface (not shown) that conceals the inner armspositioned within the construction of the spindle.

Alternatively, the spindle replacement can increase its width uponcompression of the ends toward the middle. For example, referring toFIGS. 14A and 14B, an expanding spindle replacement 310 is generallyshown. Upon compression of the end portions 312 a, 312 b towards eachother, the middle portion 314 expands. By expanding the middle portion314, the flexible core (and thus the entire flexible core rolled tissueproduct) can be given shape definition. For example, the middle portion314 can be designed to expand to within 5% of the inner diameter of theflexible core. This compression can allow the replacement spindle to beinserted into the flexible core when expanded to have a smaller diameterd_(Ext), but at the length of the spindle holder L_(SH) have a diameterd_(Comp) that gives shape definition to the flexible core. In thisembodiment, the expanding spindle can rotate with the rolled tissueproduct, instead of being stationary on the holder during use.

In one embodiment, the expanding spindle can have two tapered endportions 320 a, 320 b that are engaged to the expanding middle pieces322 a, 322 b. When compressed towards each other (to the length of thespindle holder—typically 5 and ⅛ inches), each tapered end portion movesbetween the middle pieces 322 a, 322 b separating them farther apart.Thus, the expanded middle portions 320 a, 320 b give shape definition tothe flexible core 322. Although the expanding spindle is shown usingtapered end portions in this embodiment, any method of expanding themiddle portion can be utilized. For example, the middle portion can beexpanded using an air pocket or bladder, a spring loaded system, etc.

III. Kits

When utilized as a toilet tissue roll spindle, the spindle replacementor spindle attachment can be utilized with coreless or flexible coretissue rolls for dispensing purposes. For example, the flexible coretissue product can be included in a kit along with the spindlereplacement or spindle attachment.

In one particular embodiment, a rolled tissue product having a flexiblecore can be included within a kit having a spindle attachment or spindlereplacement. The flexible core can provide sufficient strength for therolled tissue product during storage, shipment, and use, while remainingflexible primarily for packaging and storage purposes. As such, theflexible core is constructed from a synthetic polymeric sheet materialthat has a greater tensile strength than that of the tissue product.Additionally, the synthetic polymeric material of the flexible core canprotect the inner layers of the rolled tissue paper during use, whichcan allow these inner layers to be used in the ordinary course withoutdamage or waste that sometimes occurs with coreless rolled tissueproducts.

FIG. 4 shows an exemplary rolled tissue product 100 having a flexiblecore 102. Tissue web 104 is rolled about the flexible core 102. Asshown, the rolled tissue product 100 is flattened in one directioncreating an oval-like shape to the rolled tissue product 100. Due tothis flat oval-like shape, several rolled tissue products 100 can bestacked closely together for optimized packaging and storage purposes.For example, referring to FIG. 5, four rolled tissue products 100 areshown closely stacked together. As shown, the flexible core 102 of eachof these rolled tissue products 100 does not have any significant spacewithin the core. Thus, the stacked rolled tissue products 100 can bepackaged closely together without wasting space, such as shown in FIG.6. The package 106 is shown having packaging material 108 tightlywrapped around the stacked tissue products 100 which have been flattenedinto oval-like shapes.

The flexible core can be attached to the innermost layer of the tissueweb by any method. In one particular embodiment, the tissue web isadhered to the flexible core through the use of an adhesive. Anysuitable adhesive can be utilized for attaching the flexible core to thetissue web. Alternatively, the tissue web can be laminated to theflexible core via thermal bonding (heat and pressure). No matter theattachment of the tissue web to the flexible core, the attachment isstrong enough to withstand the winding process during the manufacture ofthe rolled tissue product. Particularly, the force in the machinedirection exerted on the attachment between the tissue web and theflexible core when the winding process begins can create significantstrain on the attachment. If a water-soluble polymer film is used as theflexible core, the tissue web may be attached to the core by applicationof a small amount of water to the sheet at or near the point ofattachment of the tissue sheet with the flexible core.

The tissue web can be wound onto the roll to create a rolled tissueproduct having a wide range of roll bulk. For example, the roll bulk ofthe products can be from about 4 cc/g to about 30 cc/g, such as fromabout 5 cc/g to about 25 cc/g, such as from about 6 cc/g to about 20cc/g.

The flexible core can have tabs or flaps that extend beyond the edges ofthe rolled tissue product to allow for the flexible core to be readilylocated and separated in anticipation of use. For example, referring toFIGS. 7A and 7B, the rolled tissue product 100 is shown having flaps110A and 110B located on either side of the flexible core 102. The usercan open the core formed by the flexible core through the use of tabs110A and 110B in order to insert a spindle through the flexible core fordispensing purposes. In an additional embodiment, the flexible core canbe colored (e.g., by the inclusion of a pigment, dye, or other colorantwithin or onto the surface of the core) to provide a visual discernmentof the flexible core for the user.

During use, the rolled tissue product 100 can be shaped back into acylindrical shape having a circular orientation when viewed from theside. For example, referring to FIG. 8, the rolled tissue product 100has been formed back into a circular shape when viewed from the side.Specifically, a user has formed both the tissue product 104 and theflexible core member 102 into a substantially circular shape when viewedfrom the side. As such, the tissue product 102 can be dispensed off therolled tissue product 100 by the use of conventional spindles orparticularly designed spindles (such as disclosed in further detailbelow).

A. Flexible Core

Generally speaking, the flexible core is constructed from a flexiblesheet of synthetic fibers in order to provide the required strength tothe web. The flexible sheet can include a nonwoven web of syntheticfibers, a woven web of synthetic fibers, a polymeric film, orcombinations thereof. The use of the synthetic fibers allows for addedstrength to the flexible core, when compared to the tissue productconstructed primarily of pulp fibers. For example, the flexible core canhave a tensile strength that is greater than the tensile strength of thetissue web in the machine direction. In one embodiment, the tensilestrength of the flexible core is at least twice that of the tissue webin the machine direction, such as at least five times stronger.

The use of a polymeric film allows standard production equipment to beused in manufacturing of the roll. Polymeric films can be produced anddelivered in form of an open end tube or sleeve. Such production methodsare routinely used to make plastic bags and are well known in the art.These sleeves can be manufactured such that any diameter may be created.The sleeve may or may not have a seam in the longitudinal direction, theseam may or may not have overlap. In one embodiment, this sleeve canthen be slid over a tissue winding mandrel in the same manner astraditional cores can be placed on these winding mandrels in theconverting process. Thus, minimal impact on current production equipmentis required.

The basis weight of the sheet(s) used to form the flexible core isrelatively low to allow for less material needed (reducing cost andwaste) as well as facilitating flushability and general disposal of theproduct. Additionally, the relatively low basis weights of the core canincrease the flexibility of the core. For example, the basis weight ofthe flexible core can be from about 5 grams per square meter (gsm) toabout 150 gsm, such as from about 10 gsm to about 100 gsm. For example,the basis weight of the sheet(s) used to form the flexible core can havea basis weight of about 10 gsm to about 75 gsm. The basis weight of theflexible core can be calculated by measuring the weight of the flexiblesheet material in grams and dividing by the surface area of the outerpart of the flexible core under conditions of 23° C.+/−1° C. and50%+/−5% relative humidity for a minimum of 4 hours. The surface area ofthe outer part of the flexible core can be determined by taking thecircumference of the expanded core (i.e., π times diameter) andmultiplying by the length of the roll. Alternatively, the flexible corecan be cut along a traverse line and the area of the resulting flatsheet can be measured (length times width).

Preferably the flexible core is made from a single ply of polymericmaterial. If multiple plies of polymeric material are used the basisweight of the core is determined using the weight of all plies thatcomprise the core. This weight also includes any binder materials thatare used to hold the flexible core together. The basis weight of thecore does not include any adhesives that are applied to attach thetissue web to the core.

In one particular embodiment, the flexible core includes a nonwoven webincluding synthetic fibers. The nonwoven web can be made by any numberof processes. As a practical matter, however, the nonwoven fabrics andthe fibers that make up nonwoven fabrics usually will be prepared by amelt-extrusion process and formed into the nonwoven fabric. The termmelt-extrusion process includes, among others, such well-known processesas meltblowing and spunbonding. Other methods for preparing nonwovenfabrics are, of course, known and may be employed. Such methods includeair laying, wet laying, carding, and so forth. In some cases it may beeither desirable or necessary to stabilize the nonwoven fabric by knownmeans, such as thermal point bonding, through-air bonding, andhydroentangling. The non-woven web comprising synthetic fibers may alsocomprise a binder to provide strength and integrity to the web. Suchbinders are well known in the art. Preferably the binders are watersoluble so as to facilitate the breakup of the flexible core in the web.These binders are included when calculating the basis weight of theflexible core.

As stated, the nonwoven web can primarily include synthetic fibers,particularly synthetic hydrophobic fibers, such as polyolefin fibers. Inone particular embodiment, polypropylene fibers can be used to form thenonwoven web. The polypropylene fibers may have a denier per filament ofabout 1.5 to 2.5, and the nonwoven web may have a basis weight of about17 grams per square meter (0.5 ounce per square yard). Furthermore, thenonwoven fabric may include bicomponent or other multicomponent fibers.Exemplary multicomponent nonwoven fabrics are described in U.S. Pat. No.5,382,400 issued to Pike et al., U.S. Publication no. 2003/0118816entitled “High Loft Low Density Nonwoven Fabrics Of Crimped FilamentsAnd Methods Of Making Same” and U.S. Publication No. 2003/0203162entitled “Methods For Making Nonwoven Materials On A Surface HavingSurface Features And Nonwoven Materials Having Surface Features” whichare hereby incorporated by reference herein in their entirety.

Sheath/core bicomponent fibers where the sheath is a polyolefin such aspolyethylene or polypropylene and the core is polyester such aspoly(ethylene terephthalate) or poly(butylene terephthalate) can also beused to produce carded fabrics or spunbonded fabrics. The primary roleof the polyester core is to provide resiliency and thus to maintain orrecover bulk under/after load.

In one embodiment, the nonwoven web can be combined with an additionalsheet layer, such as another nonwoven web or webs, a film(s), orcombinations thereof. When included as part of a laminate, the nonwovenweb generally provides a more cloth-like feeling to the laminate. Forexample, a film-web laminate can be formed from the nonwoven weboverlying a film layer. In one embodiment, for instance, the nonwovenweb is thermally laminated to the film to form the film-web laminate.However, any suitable technique can be utilized to form the laminate.Suitable techniques for bonding a film to a nonwoven web are describedin U.S. Pat. Nos. 5,843,057 to McCormack; 5,855,999 to McCormack;6,002,064 to Kobylivker, et al.; 6,037,281 to Mathis, et al.; and WO99/12734, which are incorporated herein in their entirety by referencethereto for all purposes.

In another embodiment, a film can be utilized within the flexible core,either alone or in combination with another layer, the film can beformed from a synthetic polymeric material that provides sufficientstrength to the flexible core. For example, the film layer may be formedfrom a thin plastic film or other flexible liquid-impermeable material.In one embodiment, the film layer is formed from a polyethylene filmhaving a thickness of from about 0.01 mm to about 0.05 mm.

The film may be formed from a polyolefin polymer, such as linear,low-density polyethylene (LLDPE) or polypropylene. Examples ofpredominately linear polyolefin polymers include, without limitation,polymers produced from the following monomers: ethylene, propylene,1-butene, 4-methyl-pentene, 1-hexene, 1-octene and higher olefins aswell as copolymers and terpolymers of the foregoing. In addition,copolymers of ethylene and other olefins including butene,4-methyl-pentene, hexene, heptene, octene, decene, etc., are alsoexamples of predominately linear polyolefin polymers.

If desired, the film may also contain an elastomeric polymer. The use ofan elastic polymer in the film can provide an elastic component to theflexible core, which can aid in the winding process of the rolled tissueproduct. For example, an elastic film can absorb some of the forcesexerted on the tissue web and the attachment between the flexible coreand the tissue web during the winding process, particularly at thebeginning of the winding process. Any suitable elastomeric polymer canbe included, such as elastomeric polyesters, elastomeric polyurethanes,elastomeric polyamides, elastomeric polyolefins, elastomeric copolymers,and so forth. Examples of elastomeric copolymers include blockcopolymers having the general formula A-B-A′ or A-B, wherein A and A′are each a thermoplastic polymer endblock that contains a styrenicmoiety (e.g., poly(vinyl arene)) and wherein B is an elastomeric polymermidblock, such as a conjugated diene or a lower alkene polymer (e.g.,polystyrene-poly(ethylene-butylene)-polystyrene block copolymers). Alsosuitable are polymers composed of an A-B-A-B tetrablock copolymer, suchas discussed in U.S. Pat. No. 5,332,613 to Taylor, et al., which isincorporated herein in its entirety by reference thereto for allpurposes. An example of such a tetrablock copolymer is astyrene-poly(ethylene-propylene)-styrene-poly(ethylene-propylene)(“S-EP-S-EP”) block copolymer. Commercially available A-B-A′ and A-B-A-Bcopolymers include several different formulations from Kraton Polymersof Houston, Tex. under the trade designation KRATON®. KRATON® blockcopolymers are available in several different formulations, a number ofwhich are identified in U.S. Pat. Nos. 4,663,220, 4,323,534, 4,834,738,5,093,422 and 5,304,599, which are hereby incorporated in their entiretyby reference thereto for all purposes. Other commercially availableblock copolymers include the S-EP-S orstyrene-poly(ethylene-propylene)-styrene elastomeric copolymer availablefrom Kuraray Company, Ltd. of Okayama, Japan, under the trade nameSEPTON®.

Examples of elastomeric polyolefins include ultra-low densityelastomeric polypropylenes and polyethylenes, such as those produced by“single-site” or “metallocene” catalysis methods. Such elastomericolefin polymers are commercially available from ExxonMobil Chemical Co.of Houston, Tex. under the trade designations ACHIEVE®(propylene-based), EXACT® (ethylene-based), and EXCEED®(ethylene-based). Elastomeric olefin polymers are also commerciallyavailable from DuPont Dow Elastomers, LLC (a joint venture betweenDuPont and the Dow Chemical Co.) under the trade designation ENGAGE®(ethylene-based) and AFFINITY® (ethylene-based). Examples of suchpolymers are also described in U.S. Pat. Nos. 5,278,272 and 5,272,236 toLai, et al., which are incorporated herein in their entirety byreference thereto for all purposes. Also useful are certain elastomericpolypropylenes, such as described in U.S. Pat. Nos. 5,539,056 to Yang,et al. and 5,596,052 to Resconi, et al., which are incorporated hereinin their entirety by reference thereto for all purposes.

If desired, blends of two or more polymers may also be utilized to formthe film. For example, the film may be formed from a blend of a highperformance elastomer and a lower performance elastomer. A highperformance elastomer is generally an elastomer having a low level ofhysteresis, such as less than about 75%, and in some embodiments, lessthan about 60%. Likewise, a low performance elastomer is generally anelastomer having a high level of hysteresis, such as greater than about75%. The hysteresis value may be determined by first elongating a sampleto an ultimate elongation of 50% and then allowing the sample to retractto an amount where the amount of resistance is zero. Particularlysuitable high performance elastomers may include styrenic-based blockcopolymers, such as described above and commercially available fromKraton Polymers of Houston, Tex. under the trade designation KRATON®.Likewise, particularly suitable low performance elastomers includeelastomeric polyolefins, such as metallocene-catalyzed polyolefins(e.g., single site metallocene-catalyzed linear low densitypolyethylene) commercially available from DuPont Dow Elastomers, LLCunder the trade designation AFFINITY®. In some embodiments, the highperformance elastomer may constitute from about 25 wt. % to about 90 wt.% of the polymer component of the film, and the low performanceelastomer may likewise constitute from about 10 wt. % to about 75 wt. %of the polymer component of the film. Further examples of such a highperformance/low performance elastomer blend are described in U.S. Pat.No. 6,794,024 to Walton, et al., which is incorporated herein in itsentirety by reference thereto for all purposes.

The film may constitute the entire flexible core, or may be part of amultilayer film, as long as the total basis weight remains relativelylow. Multilayer films may be prepared by cast or blown film coextrusionof the layers, by extrusion coating, or by any conventional layeringprocess. In one embodiment, the laminate is consists only of two layers:a nonwoven web and a film. For example, a stretched thin polypropylenefilm having a thickness of about 0.015 mm may be thermally laminated toa nonwoven web. On the other hand, in some embodiments, other layers maybe included in the laminate, so long as the resulting laminate providessufficient flexibility and strength. When present, the other layer(s) ofthe laminate can include, nonwoven webs, films, foams, etc.

In one particular embodiment, when the rolled tissue product is used astoilet tissue, the flexible core can be constructed either in whole orin part from a hydrophilic synthetic polymer(s), such as water-solubleor water-dispersible synthetic polymers. In most embodiments, acombination of water-soluble and water-dispersible polymers can beutilized. For example, the hydrophilic synthetic polymer can allow theflexible core to disintegrate when submerged in water for a period oftime (e.g., up to about 5 or 6 hours, such as from about 30 minutes toabout an hour). Thus, in this embodiment, the flexible core can besafely flushed along with the used toilet tissue.

Any water soluble polymer may be used within the films (either in wholeor in part), including but not limited to, polyvinyl alcohol, hydroxypropyl cellulose, methylhydroxypropyl cellulose, hydroxy ethylcellulose,and copolymers and mixtures thereof. Examples of suitable water solublepolymeric films include but is not limited to water soluble packagingfilms and water soluble edible films, such as but not limited to M-7031and MC-1832 films, manufactured and sold by Water-Sol, Inc,Merrillville, Ind. Another suitable biodegradable polymer is availablefrom BASF under the name Ecovio L Foam, which consists of BASF'sbiodegradable polyester and renewable polylactide.

In another embodiment, the polymeric film is made at least in part froma biodegradable thermoplastic preferably made from sustainableresources. Flexible biodegradable films are well studied in the field offlexible films; they decompose naturally avoiding environmental problemsonce they are thrown in composting areas as waste. Until recently use ofthese films has been rather rare and limited to compounds with lowmolecular weight and generally inferior mechanical properties. Recentadvances, however, have significantly increased the availability ofproducts with improved properties such that biodegradable plastic filmsare becoming used widely in products such as food wraps, trash bags andother products. The biodegradable polymeric films preferably meet orexceed the “ASTM D6400-99 Standard” according to the “Specifications forCompostable Plastics”. Such biodegradable films are now readilyavailable. An example of acceptable commercially available biodegradablefilms are the starch based films used in trash bags sold under the tradename BioBag® sold by BiogroupUSA.

Examples of suitable polymers includes, but is not limited to,polylactic acid, thermoplastic starches, polyhydroxyalkanoate (PHA), andcombinations thereof. Thermoplastic starch or TPS consists typicallyconsists of amorphous amylose/amylopectin produced by extrusion in thepresence of a plasticizer such as glycerol to help make the filmsflexible and ductile. They tend to be hygroscopic and for someapplications may require blending with a hydrophobic polymer. PLA/TPSblends and co-polymers are also known in the art and are suitable forpurposes of the present invention. Such co-polymers may be made byreacting PLA with maleic anhydride and co-extruding with TPS in thepresence of a peroxide catalyst. Other methods for creating such blendsare known in the art.

In another embodiment, the film may be made from a combination of awater soluble film such as PVA and a water-soluble polymer from anatural source. For example, pectin, a biodegradable polysaccharide canbe blended with poly(vinyl alcohol) (PVA), a synthetic polymer that isnot very biodegradable. Both materials are water soluble and thus theblend is water soluble. As films, pectin/PVA blends are more flexiblethan pectin alone and stronger than PVA alone. A blend of the twoincreases the biodegradability of PVA while maintaining its mechanicaland solubility properties. The ratio of pectin to PVA can be controlledto give the strength and flexibility properties required for thematerial to serve as the core material. Such approaches may be preferredas a simpler alternative to increasing overall biodegradability of thesystem.

B. Tissue Web

The tissue products may include single-ply tissue products ormultiple-ply tissue products. For instance, in one embodiment, theproduct may include two plies or three plies. In general, any suitabletissue web may be processed as a rolled product having a flexible corein accordance with the present disclosure. For example, in oneembodiment, the base sheet can be a tissue product, such as a bathtissue, a facial tissue, a paper towel, an industrial wiper, and thelike. Tissue products typically have a bulk density of at least 3 cc/g.The tissue products can contain one or more plies and can be made fromany suitable types of fiber.

Fibers suitable for making tissue webs comprise any natural or syntheticcellulosic fibers including, but not limited to nonwoody fibers, such ascotton, abaca, kenaf, sabai grass, flax, esparto grass, straw, jutehemp, bagasse, milkweed floss fibers, and pineapple leaf fibers; andwoody or pulp fibers such as those obtained from deciduous andconiferous trees, including softwood fibers, such as northern andsouthern softwood kraft fibers; hardwood fibers, such as eucalyptus,maple, birch, and aspen. Pulp fibers can be prepared in high-yield orlow-yield forms and can be pulped in any known method, including kraft,sulfite, high-yield pulping methods and other known pulping methods.Fibers prepared from organosolv pulping methods can also be used,including the fibers and methods disclosed in U.S. Pat. No. 4,793,898,issued Dec. 27, 1988 to Laamanen et al.; U.S. Pat. No. 4,594,130, issuedJun. 10, 1986 to Chanq et al.; and U.S. Pat. No. 3,585,104. Usefulfibers can also be produced by anthraquinone pulping, exemplified byU.S. Pat. No. 5,595,628 issued Jan. 21, 1997, to Gordon et al.

A portion of the fibers, such as up to 50% or less by dry weight, orfrom about 5% to about 30% by dry weight, can be synthetic fibers suchas rayon, polyolefin fibers, polyester fibers, bicomponent sheath-corefibers, multi-component binder fibers, and the like. An exemplarypolyethylene fiber is Pulpex®, available from Hercules, Inc.(Wilmington, Del.). Any known bleaching method can be used. Syntheticcellulose fiber types include rayon in all its varieties and otherfibers derived from viscose or chemically-modified cellulose.

Chemically treated natural cellulosic fibers can be used such asmercerized pulps, chemically stiffened or crosslinked fibers, orsulfonated fibers. For good mechanical properties in using papermakingfibers, it can be desirable that the fibers be relatively undamaged andlargely unrefined or only lightly refined. While recycled fibers can beused, virgin fibers are generally useful for their mechanical propertiesand lack of contaminants. Mercerized fibers, regenerated cellulosicfibers, cellulose produced by microbes, rayon, and other cellulosicmaterial or cellulosic derivatives can be used. Suitable papermakingfibers can also include recycled fibers, virgin fibers, or mixesthereof. In certain embodiments capable of high bulk and goodcompressive properties, the fibers can have a Canadian Standard Freenessof at least 200, more specifically at least 300, more specifically stillat least 400, and most specifically at least 500.

Other papermaking fibers that can be used in the present disclosureinclude paper broke or recycled fibers and high yield fibers. High yieldpulp fibers are those papermaking fibers produced by pulping processesproviding a yield of about 65% or greater, more specifically about 75%or greater, and still more specifically about 75% to about 95%. Yield isthe resulting amount of processed fibers expressed as a percentage ofthe initial wood mass. Such pulping processes include bleachedchemithermomechanical pulp (BCTMP), chemithermomechanical pulp (CTMP),pressure/pressure thermomechanical pulp (PTMP), thermomechanical pulp(TMP), thermomechanical chemical pulp (TMCP), high yield sulfite pulps,and high yield Kraft pulps, all of which leave the resulting fibers withhigh levels of lignin. High yield fibers are well known for theirstiffness in both dry and wet states relative to typical chemicallypulped fibers.

In general, any process capable of forming a paper web can also beutilized in the present disclosure. For example, a papermaking processof the present disclosure can utilize creping, wet creping, doublecreping, embossing, wet pressing, air pressing, through-air drying,creped through-air drying, uncreped through-air drying, hydroentangling,air laying, as well as other steps known in the art.

Also suitable for products of the present disclosure are tissue sheetsthat are pattern densified or imprinted, such as the tissue sheetsdisclosed in any of the following U.S. Pat. Nos. 4,514,345 issued onApr. 30, 1985, to Johnson et al.; 4,528,239 issued on Jul. 9, 1985, toTrokhan; 5,098,522 issued on Mar. 24, 1992; 5,260,171 issued on Nov. 9,1993, to Smurkoski et al.; 5,275,700 issued on Jan. 4, 1994, to Trokhan;5,328,565 issued on Jul. 12, 1994, to Rasch et al.; 5,334,289 issued onAug. 2, 1994, to Trokhan et al.; 5,431,786 issued on Jul. 11, 1995, toRasch et al.; 5,496,624 issued on Mar. 5, 1996, to Steltjes. Jr. et al.;5,500,277 issued on Mar. 19, 1996, to Trokhan et al.; 5,514,523 issuedon May 7, 1996, to Trokhan et al.; 5,554,467 issued on Sep. 10, 1996, toTrokhan et al.; 5,566,724 issued on Oct. 22, 1996, to Trokhan et al.;5,624,790 issued on Apr. 29, 1997, to Trokhan et al.; and, 5,628,876issued on May 13, 1997, to Avers et al., the disclosures of which areincorporated herein by reference to the extent that they arenon-contradictory herewith. Such imprinted tissue sheets may have anetwork of densified regions that have been imprinted against a drumdryer by an imprinting fabric, and regions that are relatively lessdensified (e.g., “domes” in the tissue sheet) corresponding todeflection conduits in the imprinting fabric, wherein the tissue sheetsuperposed over the deflection conduits was deflected by an air pressuredifferential across the deflection conduit to form a lower-densitypillow-like region or dome in the tissue sheet.

The tissue web can also be formed without a substantial amount of innerfiber-to-fiber bond strength. In this regard, the fiber furnish used toform the base web can be treated with a chemical debonding agent. Thedebonding agent can be added to the fiber slurry during the pulpingprocess or can be added directly to the headbox. Suitable debondingagents that may be used in the present disclosure include cationicdebonding agents such as fatty dialkyl quaternary amine salts, monofatty alkyl tertiary amine salts, primary amine salts, imidazolinequaternary salts, silicone quaternary salt and unsaturated fatty alkylamine salts. Other suitable debonding agents are disclosed in U.S. Pat.No. 5,529,665 to Kaun which is incorporated herein by reference. Inparticular, Kaun discloses the use of cationic silicone compositions asdebonding agents.

In one embodiment, the debonding agent used in the process of thepresent disclosure is an organic quaternary ammonium chloride and,particularly, a silicone-based amine salt of a quaternary ammoniumchloride. For example, the debonding agent can be PROSOFT® TQ1003,marketed by the Hercules Corporation. The debonding agent can be addedto the fiber slurry in an amount of from about 1 kg per metric tonne toabout 10 kg per metric tonne of fibers present within the slurry.

In an alternative embodiment, the debonding agent can be animidazoline-based agent. The imidazoline-based debonding agent can beobtained, for instance, from the Witco Corporation. Theimidazoline-based debonding agent can be added in an amount of between2.0 to about 15 kg per metric tonne.

In one embodiment, the debonding agent can be added to the fiber furnishaccording to a process as disclosed in PCT Application having anInternational Publication No. WO 99/34057 filed on Dec. 17, 1998 or inPCT Published Application having an International Publication No. WO00/66835 filed on Apr. 28, 2000, which are both incorporated herein byreference. In the above publications, a process is disclosed in which achemical additive, such as a debonding agent, is adsorbed ontocellulosic papermaking fibers at high levels. The process includes thesteps of treating a fiber slurry with an excess of the chemicaladditive, allowing sufficient residence time for adsorption to occur,filtering the slurry to remove unadsorbed chemical additives, andredispursing the filtered pulp with fresh water prior to forming anonwoven web.

Optional chemical additives may also be added to the aqueous papermakingfurnish or to the formed embryonic web to impart additional benefits tothe product and process and are not antagonistic to the intendedbenefits of the invention. The following materials are included asexamples of additional chemicals that may be applied to the web alongwith the additive composition of the present invention. The chemicalsare included as examples and are not intended to limit the scope of theinvention. Such chemicals may be added at any point in the papermakingprocess.

Additional types of chemicals that may be added to the paper webinclude, but is not limited to, absorbency aids usually in the form ofcationic, anionic, or non-ionic surfactants, humectants and plasticizerssuch as low molecular weight polyethylene glycols and polyhydroxycompounds such as glycerin and propylene glycol. Materials that supplyskin health benefits such as mineral oil, aloe extract, vitamin e,silicone, lotions in general and the like may also be incorporated intothe finished products.

In general, the products of the present invention can be used inconjunction with any known materials and chemicals that are notantagonistic to its intended use. Examples of such materials include butare not limited to odor control agents, such as odor absorbents,activated carbon fibers and particles, baby powder, baking soda,chelating agents, zeolites, perfumes or other odor-masking agents,cyclodextrin compounds, oxidizers, and the like. Superabsorbentparticles, synthetic fibers, or films may also be employed. Additionaloptions include cationic dyes, optical brighteners, humectants,emollients, and the like.

Tissue webs that may be formed in accordance with the present disclosuremay include a single homogenous layer of fibers or may include astratified or layered construction. For instance, the tissue web ply mayinclude two or three layers of fibers. Each layer may have a differentfiber composition. For example, referring to FIG. 9, one embodiment of adevice for forming a multi-layered stratified pulp furnish isillustrated. As shown, a three-layered headbox 10 generally includes anupper head box wall 12 and a lower head box wall 14. Headbox 10 furtherincludes a first divider 16 and a second divider 18, which separatethree fiber stock layers.

Each of the fiber layers comprise a dilute aqueous suspension ofpapermaking fibers. The particular fibers contained in each layergenerally depends upon the product being formed and the desired results.For instance, the fiber composition of each layer may vary dependingupon whether a bath tissue product, facial tissue product or paper towelis being produced. In one embodiment, for instance, middle layer 20contains southern softwood kraft fibers either alone or in combinationwith other fibers such as high yield fibers. Outer layers 22 and 24, onthe other hand, contain softwood fibers, such as northern softwoodkraft.

In an alternative embodiment, the middle layer may contain softwoodfibers for strength, while the outer layers may comprise hardwoodfibers, such as eucalyptus fibers, for a perceived softness.

An endless traveling forming fabric 26, suitably supported and driven byrolls 28 and 30, receives the layered papermaking stock issuing fromheadbox 10. Once retained on fabric 26, the layered fiber suspensionpasses water through the fabric as shown by the arrows 32. Water removalis achieved by combinations of gravity, centrifugal force and vacuumsuction depending on the forming configuration.

Forming multi-layered paper webs is also described and disclosed in U.S.Pat. No. 5,129,988 to Farrington, Jr., which is incorporated herein byreference.

The basis weight of tissue webs made in accordance with the presentdisclosure can vary depending upon the final product. For example, theprocess may be used to produce bath tissues, facial tissues, papertowels, industrial wipers, and the like. In general, the basis weight ofthe tissue products may vary from about 10 gsm to about 110 gsm, such asfrom about 20 gsm to about 90 gsm. For bath tissue and facial tissues,for instance, the basis weight may range from about 10 gsm to about 40gsm. For paper towels, on the other hand, the basis weight may rangefrom about 25 gsm to about 80 gsm.

The tissue web bulk may also vary from about 3 cc/g to 20 cc/g, such asfrom about 5 cc/g to 15 cc/g. The sheet “bulk” is calculated as thequotient of the caliper of a dry tissue sheet, expressed in microns,divided by the dry basis weight, expressed in grams per square meter.The resulting sheet bulk is expressed in cubic centimeters per gram.More specifically, the caliper is measured as the total thickness of astack of ten representative sheets and dividing the total thickness ofthe stack by ten, where each sheet within the stack is placed with thesame side up. Caliper is measured in accordance with TAPPI test methodT411 om-89 “Thickness (caliper) of Paper, Paperboard, and CombinedBoard” with Note 3 for stacked sheets. The micrometer used for carryingout T411 om-89 is an Emveco 200-A Tissue Caliper Tester available fromEmveco, Inc., Newberg, Oreg. The micrometer has a load of 2.00kilo-Pascals (132 grams per square inch), a pressure foot area of 2500square millimeters, a pressure foot diameter of 56.42 millimeters, adwell time of 3 seconds and a lowering rate of 0.8 millimeters persecond.

In multiple ply products, the basis weight of each tissue web present inthe product can also vary. In general, the total basis weight of amultiple ply product will generally be the same as indicated above, suchas from about 20 gsm to about 110 gsm. Thus, the basis weight of eachply can be from about 10 gsm to about 60 gsm, such as from about 20 gsmto about 40 gsm.

Once the aqueous suspension of fibers is formed into a tissue web, thetissue web may be processed using various techniques and methods. Forexample, referring to FIG. 10, shown is a method for making throughdriedtissue sheets. (For simplicity, the various tensioning rollsschematically used to define the several fabric runs are shown, but notnumbered. It will be appreciated that variations from the apparatus andmethod illustrated in FIG. 10 can be made without departing from thegeneral process). Shown is a twin wire former having a papermakingheadbox 34, such as a layered headbox, which injects or deposits astream 36 of an aqueous suspension of papermaking fibers onto theforming fabric 38 positioned on a forming roll 39. The forming fabricserves to support and carry the newly-formed wet web downstream in theprocess as the web is partially dewatered to a consistency of about 10dry weight percent. Additional dewatering of the wet web can be carriedout, such as by vacuum suction, while the wet web is supported by theforming fabric.

The wet web is then transferred from the forming fabric to a transferfabric 40. In one embodiment, the transfer fabric can be traveling at aslower speed than the forming fabric in order to impart increasedstretch into the web. This is commonly referred to as a “rush” transfer.Preferably the transfer fabric can have a void volume that is equal toor less than that of the forming fabric. The relative speed differencebetween the two fabrics can be from 0-60 percent, more specifically fromabout 15-45 percent. Transfer is preferably carried out with theassistance of a vacuum shoe 42 such that the forming fabric and thetransfer fabric simultaneously converge and diverge at the leading edgeof the vacuum slot.

The web is then transferred from the transfer fabric to thethroughdrying fabric 44 with the aid of a vacuum transfer roll 46 or avacuum transfer shoe, optionally again using a fixed gap transfer aspreviously described. The throughdrying fabric can be traveling at aboutthe same speed or a different speed relative to the transfer fabric. Ifdesired, the throughdrying fabric can be run at a slower speed tofurther enhance stretch. Transfer can be carried out with vacuumassistance to ensure deformation of the sheet to conform to thethroughdrying fabric, thus yielding desired bulk and appearance ifdesired. Suitable throughdrying fabrics are described in U.S. Pat. No.5,429,686 issued to Kai F. Chiu et al. and U.S. Pat. No. 5,672,248 toWendt, et al. which are incorporated by reference.

In one embodiment, the throughdrying fabric contains high and longimpression knuckles. For example, the throughdrying fabric can haveabout from about 5 to about 300 impression knuckles per square inchwhich are raised at least about 0.005 inches above the plane of thefabric. During drying, the web can be macroscopically arranged toconform to the surface of the throughdrying fabric and form athree-dimensional surface. Flat surfaces, however, can also be used inthe present disclosure.

The side of the web contacting the throughdrying fabric is typicallyreferred to as the “fabric side” of the paper web. The fabric side ofthe paper web, as described above, may have a shape that conforms to thesurface of the throughdrying fabric after the fabric is dried in thethroughdryer. The opposite side of the paper web, on the other hand, istypically referred to as the “air side”. The air side of the web istypically smoother than the fabric side during normal throughdryingprocesses.

The level of vacuum used for the web transfers can be from about 3 toabout 15 inches of mercury (75 to about 380 millimeters of mercury),preferably about 5 inches (125 millimeters) of mercury. The vacuum shoe(negative pressure) can be supplemented or replaced by the use ofpositive pressure from the opposite side of the web to blow the web ontothe next fabric in addition to or as a replacement for sucking it ontothe next fabric with vacuum. Also, a vacuum roll or rolls can be used toreplace the vacuum shoe(s).

While supported by the throughdrying fabric, the web is finally dried toa consistency of about 94 percent or greater by the throughdryer 48 andthereafter transferred to a carrier fabric 50. The dried basesheet 52 istransported to the reel 54 using carrier fabric 50 and an optionalcarrier fabric 56. An optional pressurized turning roll 58 can be usedto facilitate transfer of the web from carrier fabric 50 to fabric 56.Suitable carrier fabrics for this purpose are Albany International 84Mor 94M and Asten 959 or 937, all of which are relatively smooth fabricshaving a fine pattern. Although not shown, reel calendering orsubsequent off-line calendering can be used to improve the smoothnessand softness of the basesheet.

In one embodiment, the reel 54 shown in FIG. 10 can run at a speedslower than the fabric 56 in a rush transfer process for building crepeinto the paper web 52. For instance, the relative speed differencebetween the reel and the fabric can be from about 5% to about 25% and,particularly from about 12% to about 14%. Rush transfer at the reel canoccur either alone or in conjunction with a rush transfer processupstream, such as between the forming fabric and the transfer fabric.

In one embodiment, the paper web 52 is a textured web which has beendried in a three-dimensional state such that the hydrogen bonds joiningfibers were substantially formed while the web was not in a flat, planarstate. For instance, the web can be formed while the web is on a highlytextured throughdrying fabric or other three-dimensional substrate.Processes for producing uncreped throughdried fabrics are, for instance,disclosed in U.S. Pat. No. 5,672,248 to Wendt, et al.; U.S. Pat. No.5,656,132 to Farrington, et al.; U.S. Pat. No. 6,120,642 to Lindsay andBurazin; U.S. Pat. No. 6,096,169 to Hermans, et al.; U.S. Pat. No.6,197,154 to Chen, et al.; and U.S. Pat. No. 6,143,135 to Hada, et al.,all of which are herein incorporated by reference in their entireties.

In FIG. 10, a process is shown for producing uncreped through-air driedtissue webs. For example, referring to FIG. 11, one embodiment of aprocess for forming wet creped tissue webs is shown. In this embodiment,a headbox 60 emits an aqueous suspension of fibers onto a forming fabric62 which is supported and driven by a plurality of guide rolls 64. Avacuum box 66 is disposed beneath forming fabric 62 and is adapted toremove water from the fiber furnish to assist in forming a web. Fromforming fabric 62, a formed web 68 is transferred to a second fabric 70,which may be either a wire or a felt. Fabric 70 is supported formovement around a continuous path by a plurality of guide rolls 72. Alsoincluded is a pick up roll 74 designed to facilitate transfer of web 68from fabric 62 to fabric 70.

From fabric 70, web 68, in this embodiment, is transferred to thesurface of a rotatable heated dryer drum 76, such as a Yankee dryer.

In this embodiment, as web 68 is carried through a portion of therotational path of the dryer surface, heat is imparted to the webcausing most of the moisture contained within the web to be evaporated.Web 68 is then removed from dryer drum 76 by a creping blade 78. Crepingweb 78 as it is formed further reduces internal bonding within the weband increases softness.

Creping the tissue web as shown in FIG. 10 increases the softness of theweb by breaking apart fiber-to-fiber bonds contained within the tissueweb. Applying the additive composition to the outside of the paper web,on the other hand, not only assists in creping the web but also adds drystrength, wet strength, stretchability and tear resistance to the web.

According to the process of the current disclosure, numerous anddifferent tissue products can be formed. For instance, the tissueproducts may be single-ply wiper products. The products can be, forinstance, facial tissues, bath tissues, paper towels, napkins,industrial wipers, and the like. As stated above, the basis weight canrange anywhere from about 10 gsm to about 110 gsm.

In one embodiment, tissue webs made according to the present disclosurecan be incorporated into multiple-ply products. For instance, in oneembodiment, a tissue web made according to the present disclosure can beattached to one or more other tissue webs for forming a wiping producthaving desired characteristics. The other webs laminated to the tissueweb of the present disclosure can be, for instance, a wet-creped web, acalendered web, an embossed web, a through-air dried web, a crepedthrough-air dried web, an uncreped through-air dried web, an airlaidweb, and the like.

These and other modifications and variations to the present inventionmay be practiced by those of ordinary skill in the art, withoutdeparting from the spirit and scope of the present invention, which ismore particularly set forth in the appended claims. In addition, itshould be understood that aspects of the various embodiments may beinterchanged both in whole or in part. Furthermore, those of ordinaryskill in the art will appreciate that the foregoing description is byway of example only, and is not intended to limit the invention sofurther described in such appended claims.

1. A spindle attachment for use with a traditional spindle, the spindleattachment comprising an elongated tube defining two opposing endportions separated by a middle portion, wherein each end portion istapered at an angle of less than 55° and the middle portion issubstantially cylindrical in shape, and wherein the elongated tubedefines a circular opening that extends through the center of theelongated tube from one end portion to the opposition end portion, theopening having an inner diameter of from about 0.75 inches to about 1.25inches.
 2. A spindle attachment as in claim 1, wherein the middleportion defines an outer surface having an outer diameter of about 1.25inches to about 2 inches.
 3. A spindle attachment as in claim 2, whereinthe outer surface of the middle portion has an outer diameter of about1.5 inches to about 1.75 inches.
 4. A spindle attachment as in claim 2,wherein the outer surface of the middle portion has an outer diameter ofabout 1.45 inches to about 1.6 inches.
 5. A spindle attachment as inclaim 1, wherein each end portion and the middle portion collectivelydefine an outer surface coated with an lubricating coating that lowersthe coefficient of friction of the outer surface.
 6. A spindleattachment as in claim 1, wherein each end portion and the middleportion collectively define a grooved outer surface.
 7. A spindleattachment as in claim 1, wherein each end portion is tapered at anangle of about 20° to about 40°.
 8. A kit comprising the spindleattachment as in claim 1; and at least one rolled tissue product, therolled tissue product comprising a nonwoven tissue web comprising pulpfibers wound about a flexible core, wherein the flexible core comprisesa polymeric sheet of synthetic polymers, wherein the nonwoven tissue weband the flexible core are attached to each other at an inner layer ofthe nonwoven tissue web by an attachment mechanism, and wherein thetissue sheet defines a machine direction, the tissue sheet having atensile strength in the machine direction that is weaker than thestrength of the flexible core.
 9. A kit as in claim 8, wherein themiddle portion defines an outer surface having an outer diameter, andwherein the flexible core defines an inner diameter that is from about0.1% to about 5% greater than the outer diameter of the outer surface ofthe middle portion.
 10. An armed spindle for use in place of atraditional spindle, the armed spindle comprising a pair of opposingpegs that define a center axis of the armed spindle that extends throughthe center portion of each opposing peg, and at least 3 arms, each armbeing in contact with each opposing peg, wherein each arm has a pair ofend portions that extend away from the center axis of the armed spindleto a middle portion; wherein the at least four arms are configured torotate about the center axis from a substantially flat position to arotating position where the arms are spaced apart in a substantiallyequal distance.
 11. An armed spindle as in claim 10 having 4 arms,wherein the 4 arms are configured to rotate about the center axis from asubstantially flat position to a cross-like shape.
 12. An armed spindleas in claim 10 having 6 arms, wherein the 6 arms are configured torotate about the center axis from a substantially flat position to ahexagonal-like shape.
 13. An armed spindle as in claim 10, wherein eacharm defines a surface coated with a lubricating coating that lowers thecoefficient of friction of the surface.
 14. An armed spindle as in claim10, wherein oppositely positioned arms move in concert with each other,but independently from adjacently positioned arms.
 15. A kit comprisingthe spindle attachment as in claim 10; and at least one rolled tissueproduct, the rolled tissue product comprising a nonwoven tissue webcomprising pulp fibers wound about a flexible core, wherein the flexiblecore comprises a polymeric sheet of synthetic polymers, wherein thenonwoven tissue web and the flexible core are attached to each other atan inner layer of the nonwoven tissue web by an attachment mechanism,and wherein the tissue sheet defines a machine direction, the tissuesheet having a tensile strength in the machine direction that is weakerthan the strength of the flexible core.
 16. A kit as in claim 15,wherein the middle portion defines an outer diameter when in therotating position, and wherein the flexible core defines an innerdiameter that is from about 0.1% to about 5% greater than the outerdiameter defined by the arms in a rotating position.
 17. An expandingspindle comprising a pair of end portions and a middle portion, themiddle portion having an extended diameter, wherein the middle portionexpands to a compressed diameter from the extended diameter when the endportions are compressed towards each other.
 18. An expanding spindle asin claim 17, wherein the middle portion comprises at least two separatepieces, and wherein each end portion is tapered such that the separatemiddle portion pieces expand when the tapered end portions arecompressed toward each other.
 19. An expanding spindle as in claim 17,wherein the middle portion expands during compression of the endportions toward each other due to an air bladder positioned within themiddle portion and between the end portions.